Panel



Patented Oct. 4, 1938 OFFICE PANEL Harry B. Denman, Birmingham,

Mich., assignor to Detroit Gasket & Manufacturing Company, Detroit, Mich., a vcorporation ol' Michigan Application January 7, 1935, Serial No. 782

`1o claims.

The present invention relates to panels and more particularly those associated with the interiors of motor vehicles where a permanent, attractive appearance must be preserved under relatively diilicult and widely varying conditions of temperature and moisture, as well as shock and Vibration.

Thus an object of the invention is to produce a panel substantially free of warping tendencies,

and which is not affected by moisture and heat or cold.

Ordinarily, panels are made by indenting a base material to produce a raised configuration, over which. the trim cloth is adhered. Frequently, it is diicult to produce a uniform indentation as where the conguration includes sharp outlines and moreover, the pressed-in portion or portions exert a normal tendency to return or fade under conditions of usage. As a result, a uniformly neat and attractive appearance for a given design is sometimes impossible and when the indentations contract or fade, the cloth becomes loose and saggy, i. e., it separates from the panel body.

These obstacles are overcome by the present invention wherein the sharpest configuration is easily molded and, moreover, is solid or substantially solid so that (l) there is neither difnculty in forming a uniform contour nor (2) any 80 possibility of objectionable fading. Moreover, the moldable material exhibits no tendency to warp or distort and where used with a base sheet, it has suiiicient strength to overcome the possibilities of warping or distortion of the base under extreme conditions.

Further characteristics of the moldable material are its temperature and moisture resistance, and a resilience resembling hard rubber which is compensatory under conditions of use. Further, the moldable material is such that the `trim cloth may be easily adhered by any satisfactory, resistant adhesive so'that at all times a neat and permanently attractive appearance is presented.

Referring to the drawing: Figure 1 is an elevation of a panel in ,accordance with the present invention;

Figure 2 is a sectional view of the panel; Figure 3 is an elevational view partly broken 50 away with the trim cloth removed;

Figure 4 is a sectional view of a laminated panel material;

Figure 5 is a sectional view similar to Figure 4 showing the panel provided with configurations 55 or raised portions;

Figure 6 is a sectionalview of a further form of panel material; f Figure 7 is a sectional view similar to Figure 6 showing the panel provided with configurations or raised portions; 5

Figure 8 is a sectional view of a modification; this panel may also be used in connection with Figures 2, 4, 5 and 6. l

Figure 9 is a sectional view of a further modification; this panel may also be used in connec- 10 tion with the structures shown in Figures 2; .4, 5 and 6.

Referring to the drawing, I have illustrated in Figure 1 at I0 a panel in accordance with this f invention, in position yon the door of an auto- 15 mobile. It is to be understood that the panel of this application is not restricted to motor cars but may be used with any-other structure.

Referring to Figures 2 and 3, this panel comprises a base Il of any suitable stiff material, 20 but preferably a stii paper-or fiber board of suitable gauge or thickness. The ber board is preferably rendered waterproof by incorporation in the fibers of a suitable water resistant agent, or it is impregnated or coated with such a water 25 resistant material. 'I'here are any number of satisfactory waterproofing agents commercially available for this purpose which form a continuous film. l

The panel In is provided with a layer -lz of 30 moldable material forming a raised configuration. As shown in- Figures l, 2 and 3, the riser consists of a strip or spaced strips which may be continuous about the marginof the base asv shown, or discontinuous and applied upon any 35 desired spaced areas of the base Il, i. e. thel sectional designs or raised portions are attached to the base without covering the whole area thereof. 40

The configuration is therefore produced by superposing on the base Il and adhering thereto a layer I2 molded to any desired form' and positioned with respect to the base, i. e., covering any required areas thereof, to give the appropriate predetermined contour and appearance.

The layer I2 of moldable material is preferably an unvulcanized mixture of reclaimed rubber, bers, and a suitable plasticizing, waterproofing agent such as asphalt, for example, gilsonite. This mixture, on setting, has the resilience and rmnesscharacteristics of hard rubber. ,It may be premolded and united to `the base Il by a l suitable adhesive or directly molded upon the base Il. The adhesive is applied either to the base or to the moldable composition or both, or

the mixture may be of itself adhesive.

In some cases, a v'ulcanizing agent is used in the mixture vand adherence obtained by vulcanization of the layer I2 to the base II.

The area. of the layer I2 of moldable material, is in some cases, coextensive with the base II, as in Figures 4 and 5. Again the layer I2 comprises a single narrow strip or strips, the latter in some cases in connected relation, superposed upon and adhered to the base. Where, as in Figures 2, 5 and'7, the risers are in multiple, they are formed integral with and connected by a relatively thin web I3, or as shownl inI Figure 9, the risers are adhered to a separate sheet or web I3' of larger area than the web I3; the risers may likewise. be formed integral with the larger web I3 as shown in Figure 2, for example. The layerA I2, including in some cases a web I3vor I3', in any instance, is adhered to the base in the manner already described.

Over the board Il having the layer I2 comprising the configuration or raised portions is superposed a trim cloth I4 as in Figure 2. This trim cloth is adhered to the board I I and the layer I2 substantially throughout the area `of they cloth, as shown in Figure 2, and its edges are carried over and adhered to the back of the board as at I6. A neat and clean-cut t is thus produced bringing out sharply the attractive' contour of the board. The adhesive may be applied to the cloth or to the layers I2, I3, or both; again the rubber fiber-asphalt mixture may be inherently adhesive or be vulcanizable, so as to secure, in all cases, the required coextensive adhesionof -cloth to the board and its contoured surface.

In some cases a cloth finish is not used and instead thereof a coating of temperature and weather resistant lacquer or varnish of an appropriate color is employed.

Likewise, the layer I2 whether of spaced configurations or a coextensive layer has sometimes a suitable color incorporated therein, whereby a trim cloth or coating need not be used.

Referring to Figure 4, the board II is coated or covered with a coextensive, relatively thin layer I2 of the moldable material which may be plain if desired', i. e., devoid of raised portions or configurations. l

Referring to Figure 5, the board II shown in Figure 4 is provided with a coextensive layer I2 of moldable material having integral molded riser portions to give the desired configuration I 2. The layer I2 may be preliminarily molded to the contour shown, or any other desired contour, or the raised portions I2 may be molded to form after or simultaneously with the application of moldable material to the board II.

In Figure 6, there is illustrated a plain layer of 'moldable material winch, in some cases, is quite satisfactory for panel purposes exhibiting freedom from warping,.and resistance to the factors of heat and moisture to which panels are normally subjected. In Figure '7, the layer I2 is thicker, but otherwise similar to the layer I2 illustrated in Figure 5, the moldable material being formed withthe integral raised portions or configurations I2.

Where the layer I2 is coextensive with the board II as shown in Figures 4 and 5, or a webA I3 or I3' is used as shown in Figures 2 and 9, the layer or web, as the case may be,4 is preferably thinner than the layer of moldable material I2, as shown in Figures 6, 7 and 8.

In Figure 8, I have illustrated a layer I2 similar to that shown in Figure 6, but embossed or pressed to have configurations l1. formed therein. 'I'his layer I2 maybe (1) used alone; (2) superposed upon and united to a board II, or (3) superposed upon and united to another moldable material layer I2, i. e., a plain base as shown in Figure 6, producing a very acceptable panel, in all cases. The moldable material, as stated, is heat and moisture resistant and permanent, i. e., the hollowindentations I'I do not exhibit any tendency to return or fade such as is frequently encountered where a fibre board is pressed in or embossed.

In Figure 9, the layer I2 includes the raised portions or configurations either integral with the web I3 or adhesively united thereto. It is to be noted that the area of the layer I2 in Figure 9 is somewhat greater than the area of the layer I2 in Figure 2, the web whether integral or separable with respect to the raisd portions extending'literally from opposite sides thereof as shown at It is to be observed that the molded raised portions of the layer I2 as shown in Figures 2, 5, 7 and 9 are solid and this, of course, assures that there will be no substantial contraction or return, i. e., so-called fading" of the configurations such as would destroy the adherence of the cloth and produce a looseness or sagging to mar the appearance of the panel.

The permanency and strength of the moldable layer I2 insures a similar resistance to contraction or fading in the case of a panel constructed in accordance with Figure 8.v

The moldable material of the layer I2, as heretofore stated, upon setting, has the resilience and firmness of hard rubber. When united to the board II or to another layer of moldable material I2, it acts to reinforce the base and retard any possible distortion or warping. Because of the resilience and flexibility of the material, it is compatible with the ordinary stiff paper board sheets and will flex and bend suiiiciently after the mannerof such sheets to permit the panel to be vproperly positioned and attached on the body structure.

With respect to a panel comprising the layer I2, as shown in Figure 8, either used alone or combined with a board Il or a baselayer I2 of moldable material, the firmness and strength of the configurated layer, whether it be coextensive or simply have a strip form is quite marked. While I prefer that the configurations be solid, as shown in Figure 2 for example, there are many instances where a structure of the type shown in Figure 8 is useful either alone or in combination as described.

It is to be noted that the congurations or contours are very easily produced, are permanent, and the rubber fibre, asphalt mixture is compatible with most adhesives whereby ther moldable mixture is readily united to the base and to the trim` cloth I4. It is understood, of course, that whenever the panels described will be covered with the trim cloth I4, that this member will be adhesively united to the board and to the moldable mixture upon the board, so-thatthe adhesive union is co-extensive with the area of the board and configurations and the cloth. A neat, close fitting appearance, bringing out sharply and clearly a uniform contour, is obtained and since there is but little opportunity for warping in view of the reinforcing action of the layer I2 upon the base and substantially no possibility of fading due t0 the permanent character of the layer I2, this adhesive union and hence the nice appearance of the panel is preserved.

In preparing the reclaimed rubber-fibre-asphalt mixture, the reclaimed rubber and gilsonite, for example, are fed into a suitable rubber .mill and worked cold for about flve minutes. As one example, thirty parts of'rubber to fifteen parts of gilsonite are used. After a thorough mixing, the fibres such as ground paper or any other fibrous material or scrap, and/or comminuted cork, are added gradually in the amount of about fifty parts. The mixing operation consumes about twenty minutes.

In addition to the fibrous material, a filler, such as Whiting, is used in some cases in approximately five parts.

After the complete mixing, in the course of which the temperature, due to working, may go up to F., the mixture is taken to a calendering machine and sheeted out to the desired gauge. 'Ihe mixture, as will be understood, is warm and the temperature of the calendering rolls may be as high as 150 F. as desired. Following calendering, the sheets are cold-pressed or molded to the desired form while warm. The warming temperature or the temperature of the mixture should not exceed 150 F.

'Ihe unvulcanized moldable or plastic mass will harden to the condition of ordinary hard rubber without employment of a vulcanizing agent and at normal atmospheric temperature and pressure, i. e., no heating or other treating of the material is required in order to cure or set it. This, it will be appreciated, is of great importance in manufacture, whether the layer I2 is preformed with configurations or coated upon the base sheet and the configurations molded thereon.

Thus, in carrying out the invention, a coextensive layer or a strip layer or a layer of any desired configuration may be preliminariiy formed and then adhesively united to the base, whether it be a board II or a layer I2 of the moldable material. Again, the moldable material may be applied to the base and the configuration then produced on the layer I2 simultaneously with its adhesion to the base or thereafter.

In some cases, I apply a configuration layer or a coextensive layer to each side of the base.l It is to be noted that where the layer I2 is coextensive with the base, that it is of less thickness than the base and the coniigurated portions. Of course, the thickness of the layer I2 may be of any desired gauge.

While I have referred to an unvulcanized moldable mixture and prefer this, since the composition described on setting is hard and resilient after the manner of hard rubber, and quite strong, in some cases I utilize a vulcanizing agent in the mixture such as sulphur. A somewhat similar final set product is obtained and where the vulcanizing agent is present, in some cases it is possible to eliminate the use of an adhesive for securing the layer I2 to the base or the trim cloth to the layer I2, since the adhesive union will be obtained by the vulcanizing action, i. e., the rubber fiber composition will be vulcanized with the panel in assembled relation.

The board II employed is preferably one constructed to be very resistant to warping and, as stated, waterproof. The moldable composition described possesses characteristics similar to that of the board, so as to be compatible therewith whereby flexing or expansion and contraction will not result in cracking of either layer nor breaking down of the adhesive union.

In this connection. may be used and likewise the percentage ratio of materials forming the moldable layer I2 may be varied. For example, the layer I2 may have increased or decreased stiffness by changing the bre content. Y

In all cases, a panel structure is obtained which is (l) highly resistant to warping, (2) free from any fading characteristics, and (3) weather resistant and vibration resistant. All of these factors are important when it is considered that the panelof the present invention, because of the moldable material, is susceptible oi' providing any desired contours regardless oi.' the complicated or sharp angle characteristics required.

I also preparea mixture comprising rubber, an asphalt such as gilsonite, and cork, the cork being comminuted or granulated and comprising substantially 10% by weight, i. e., approximately 35% by volume. 'I'his mixture also comprises in some cases rubber, an asphalt, fibrous material, for example paper bres, and comminuted cork in the percentage or weight just specified.

As stated, a facing is applied tothe surface of the panel such as (l) a trim cloth, or (2) a resistant coating or finish of suitable color, or (3) the layer I2 whether it (a) covers the whole area a board ci varying pliancy i of the base or (b) is applied to spaced areas thereof has incorporated When the layer I2 includes a color and is applied to leave exposed portions of the base, the base may have incorporated therein or be coated or nished with the same or a contrasting color.

Further modifications of the invention may, of course, be made all of which are comprehended Within the scope of the appended claims.

I claim: I

1. A panel comprising a relatively stil! base. a layer of a moldable composition material adhered to said base and forming a raised portion or configuration, and a trim cloth overlying said sheet and said layer of moldable material and united to said sheet.

2. A panel comprising a layer oi' stili sheet material and a layer of a composition of rubber and fibers including a waterproofing agent united to said sheet at spaced areas of the sheet.

3. A panel comprising a layer of stiii' sheet material, a layer comprising a composition of rubber and fibers including a waterproofing agent, said layer having integral therewith a configuration or raised portion extending above the plane of the sheet. n i,

4. A panel comprising a layer of stili.' sheet material, a coextensive layer comprising a moldable composition of rubber and fibers including a waterproofing agent, portions of said layer being molded and raised above the plane of said sheet.

5. A panel comprising a layer of stiff, sheet material. a layer comprising a composition of rubber and fibers including a waterproofing agent, said layer having a configuration or raised contour extending above the plane of the sheet and a web portion adhered to the surface of the sheet.

6. A panel comprising a layer of a composition of rubber and fibers including a waterproofing agent, portions of said layer being indented to form/configurations' extending laterally with respect to the plane of the layer.

7. A panel comprising a layer of a composition of rubber and fibers including a waterproofing agent, portions of said layer being indented to form configurations extending laterally with retherein a suitable color.

points and overlying spaced' spect to the plane of the layer, and a base to which said layer is united. y p

8. A panel comprising a relatively sti!! base, a layer of a moldable, resilient, composition material including rubber adhered to said base and forming a raised portion or conguration at spaced points overlying spaced areas of the base.

9. A panel comprising a layer of stii! sheet material, a layer comprising a composition of rub- 10 ber, comminuted cork and ilbers including a wa- HARRY B. DENMAN. l0 

